Carton unloader



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CARTON UNLOADER 5W. VAN V. D/CEJ Dec. 3, 1957 s. v. DICE 2,815,140*

CARTON UNLOADER Filed oet. 2e, 1955 'r sheets-sheet 7 United States Patent O CARTON UNLOADER Sylvan V. Dice, Quincy, lll., assiguor to A-B-C Packaging Machine Corporation, Quincy, lll., a corporation of Illinois Application October 26, 1953, Serial No. 388,351

14 Claims. (Cl. 214-304) The present invention relates generally to unpacking apparatus, and more particularly to an automatic carton unloading machine provided with novel flap opening devices by means of which ya closed carton may be fed into the machine, have all of its lower flaps opened outwardly without damage thereto, and removed so as to leave the original contents of the carton on a conveyer for discharge at a point of use.

Briey, the invention contemplates a machine in which a carton is received at one end and advanced to an indexing station where it is engaged by a pusher bar which moves it through the machine. Conventional outer flap plows are provided to open the lower side flaps so that the carton may then rest upon its end flaps. Novel means are provided whereby the trailing end Hap is opened by allowing its leading edge to drop into a slot so that the forward movement of the carton is effective to pivot the flap to a full open position. The liap at the leading end of the carton is opened in a generally similar manner, except that the slot for receiving the flap is incorporated in a chain conveyer which moves in the same direction as the carton, but at greater speed. Suction devices are provided for ensuring proper entry of the end aps into the slots. With all ilaps opened, the contents of the carton are disposed on a moving belt conveyor, and the carton is lifted therefrom and discharged at a point removed from the unloaded contents.

A carton unloader of the type herein contemplated finds particular use in a packing or bottling plant where containers such as cans or bottles are customarily received in cartons to be unloaded, filled and sealed, and repacked in the original cartons.

It is an object of the present invention to provide a novel carton unloader which is fully automatic in its function of receiving a loaded carton, opening the flaps thereof, disposing the contents of the carton on a moving conveyer, and removing the carton.

It is another object of the invention to provide a carton unloader having novel automatic means for opening the bottom flaps of a loaded carton without damage either to the carton or to the contents thereof.

It is another object of the invention to provide novel means for opening the trailing bottom end flap of a moving carton.

It is another object of the invention to provide novel means for opening the leading bottom end flap of a moving carton.

It is another object of the invention to provide a novel carton flap opening mechanism which incorporates a slot for receiving a bottom liap during relative movement between the carton and the slot.

It is another object of the invention to provide a novel carton iiap opening mechanism which includes a moving chain having a slot for receiving a bottom carton liap and which is adapted to receive the contents of an unloaded carton. i

The foregoing and additional objects and advantages will be apparent form the following description taken in ice 2 conjunction with the accompanying drawings, in which:

Fig. 1 is a fragmentary top plan view of a carton unloader constructed in accordance with the teachings of the present invention, the view being directed to the charging, or carton receiving, end of the unloader, certain elements being omitted in the interests of clarity;

Fig. 2 is a fragmentary top plan view similar to Fig. l, but directed to the discharge end of the unloader and showing that portion of the unloader which extends on to the right of Fig. l;

Fig. 3 is a fragmentary sectional elevation taken generally along the line 3--3 of Fig. l;

Fig. 4 is a fragmentary sectional elevation taken generally along the line 4 4 of Fig. 2;

Fig. 5 is an enlarged fragmentary sectional elevation showing with added detail a portion near the left end of Fig. 4;

Fig. 6 is a fragmentary vertical sectional view taken generally along the lines 6-6 of Figs. l and 3;

Fig. 7 is a vertical sectional view taken generally along the lines 7-7 of Figs. 2 and 4;

Fig. 8 is a fragmentary vertical sectional view taken generally along the lines 8 8 of Figs. 2 and 4;

Fig. 9 is an enlarged fragmentary vertical sectional view taken generally along the line 9-9 of Fig. 4, showing with added detail a portion near the bottom of Fig. 8;

Fig. 10 is an enlarged fragmentary top plan view showing with added detail a portion at the left end of Fig. l;

Fig. 1l is an enlarged fragmentary top plan view showing with added detail a portion near the top left of Fig. l;

Fig. 12 is a vertical sectional view taken generally along the line 12-12 of Fig. 11;

Fig. 13 is an enlarged fragmentary top plan view showing with added detail a portion near the bottom left of Fig. 1;

Fig. 14 is a vertical sectional view taken generally along the line 14-14 of Fig. 13;

Fig. l5 is a schematic sectional elevation showing the positional relationship of the mechanism for opening the bottom end flaps of a moving carton;

Figs. 16 through 19 are sequential schematic sectional elevations illustrating the opening of a trailing end carton ilaps; and

Figs. 20 through 25 are sequential schematic sectional elevations illustrating the opening of a leading end carton flap.

Referring to the drawings more particularly by reference numerals, the numeral 30 indicates generally a carton unloader incorporating the teachings of the present invention. The unloader 30 comprises a main framework 32 upon which are mounted, in order, a receiving conveyer section 34, a side ap opening section 36, a trailing end flap opening section 38, a leading end flap opening section 40, and an article receiving conveyer 42. The framework 32 also supports a flight chain assembly 44 which is adapted to move cartons from the receiving conveyer section to a point of discharge, as will appear. The various operating sections of the unloader 3i) are interconnected by power transmitting means driven from a single prime mover 46. In addition, each of the trailing and the leading end ap opening sections incorporates an auxiliary vacuum unit which includes air cylinders, as will be described hereinafter.

In the following portions of this description, reference will occasionally be made to the front or rear of the uuloader 30, as well as to the right and left hand sides thereof. It is to be understood, therefore, that the front of the unloader 30 is that end which `comprises the ieceiving conveyer section 34 and that the rear of the unloader 30 is that end which comprises the article receiving conveyer 42. The right hand and left hand sides of the 3 unloader 30 are to be construed as such when viewed from the front end thereof.

The main framework 32 comprises six upstanding channels designated as right hand front, center, and rear legs 50, 51 and 52, respectively, and left hand front, center and rear legs 53, 54 and 55, respectively. These legs are disposed symmetrically with respect to the longitudinal center line of the unloader 30, and are interconnected in front, center and rear pairs by means of horizontally disposed tie angles 56 which extend laterally beyond the legs 50 through 55 for supporting attachment to a right hand side channel 60 and a left hand side channel 61. The side channels 60 and 61 are preferably formed from sheet metal and, as is clear from the drawings, extend substantially the full length of the unloader 30. Added cross bracing for the legs 50 through 55 may be provided in the form of cross braces such as 62 shown in the drawings to extend between the legs 51 and 54. The structural integrity of the framework 32 is still further enhanced by various cross members secured between the channels 60 and 61, as will be hereinafter described.

In addition to the above described main framework 32, the unloader 30 here illustrated includes an auxiliary framework (Figs. 2 and 4) for supporting the prime mover 46 along with certain associated driving elements, and also a motor driven vacuum pump. This auxiliary framework comprises upstanding right hand and left hand auxiliary legs 65 and 66 disposed flush with the outside of the side channels 60 and 61, respectively. The legs 65 and 66 are interconnected by means of a tie member 67 which supports one end of each of two longitudinally extending carrier members 68 and 69, the other end of these carrier members being secured to the legs 52 and 55, respectively.

The receiving conveyer section 34 of the unloader 30 comprises that portion of the unloader 30 which is disposed forwardly of the front legs 50 and 53. As is clear from the drawings, the side channels 60 and 61 extend substantially forwardly of these legs 50 and 53 where they provide appropriate support for the operating mechanism of the receiving conveyer section 34.

Referring now particularly to Figs. 1 and 3 of the drawings, the receiving conveyer section 34 includes right hand and left hand feed channels 70 and 71 disposed parallel to and between the main side channels 60 and 61. The feed channels 70 and 71 are supported at their forward ends by a front feed channel support 72 and at their rear ends by a rear feed channel support 73 secured between the legs 50 and 53. Between them, the feed channels 70 and 71 support two feed idler pulleys 75, one at each end of the feed channel arrangement, and a series of conventional feed belt rollers 76 in horizontal spaced arrangement between the pulleys 75. In addition, the feed channels 70 and 71 support a feed belt idler roller 77 and a feed belt tightener roller 78, these latter rollers being disposed below the horizontally spaced pulleys 75 and feed belt rollers 76. The tightener roller 78 is preferably mounted for adjustable movement normal to its lateral extent and is provided with an appropriate tightener bracket 79.

A feed belt drive shaft 85 disposed transversely between the side channels 60 and 61 is supported from the latter by means of appropriate bearings 86. One end of the shaft 85 extends through and beyond the right hand channel 60 and has a beveled gear 87 mounted theron. The shaft 85 is rotatable and, as shown in the drawings, passes under the feed channels 70 and 71. A feed belt drive pulley 90 disposed between and below the feed channels 70 and 71 in alignment with the feed idler pulleys 75 is mounted on for rotation with the shaft 85, being thereby adapted to drive a feed belt 91 disposed around these several pulleys and over the tops of the rollers 76, as illustrated. As is clear from the drawings, the rollers 77 and 78 guide the feed belt 91 suiciently around the periphery of the drive pulley to provide an eflicient frictional drive.

In addition to the drive pulley 90, the shaft 85 has secured thereto a feed cam 93 and a flap lifter cam 94, the former being disposed on the right hand side between the feed channel 70 and the side channel 60 and the latter being disposed on the left hand side between the feed channel 71 and the side channel 61. Both of these cams are secured for rotation with the shaft 85. The cam 94 comprises a plate-like body portion having a peripheral shape substantially as shown in Fig. l2 and is adapted, for a purpose to appear, to make peripheral contact with a cam roller 95 mounted on a cam follower arm 96.

The feed cam 93 has a radially extending peripheral flange 97 provided with a lateral offset 98, as best shown in Figs. l and 13. The peripheral flange 97 is embraced by a pair of rollers 99 mounted on a slide member 100, as best shown in Fig. 14.

The slide member 100 is shaped as clearly shown in Figs. 3, 13 and 14 of the drawings and includes a mounting boss 102 by means of which it is slidably mounted on a shaft 103 appropriately secured in the side channels 60 and 61. Additionally, the slide member 100 includes a depending holding arm 104 having a bifurcated free end adapted to embrace the feed shaft 85 and thereby to prevent rotation of the member 100 about the axis of the shaft 103. The member 100 also includes an upstanding clamping portion 106 which receives a feed bar 107, securing the same in appropriate adjusted longitudinal position by means of bolts 108. The inner end of the feed bar 107 is provided with a pusher plate 109, and it is evident that as the feed cam 93 is rotated, the pusher plate 109 will be periodically displaced from the full line position to the dotted line position as shown in Fig. 13, and returned.

The unloader 30 includes a right hand guide rail assembly 112 and a left hand guide rail assembly 113 each of which extends from the front of the machine, past the several ap opening mechanisms, to the forward end of the article receiving conveyer 42. The guide rail assem* blies 112 and 113 are adjustably mounted on three guide rail adjustment shafts 114, and 116 extending transversely of the unloader 30 and rotatably supported in appropriate bearings 117 secured to the side channels 60 and 61. Each of the guide rail adjustment shafts 114 and 115 is provided with a right hand threaded portion on one side of its center and with a left hand threaded portion on the other side of its center, as is also the guide rail adjustment shaft 116, except that the threaded portions of the latter are disposed more toward the ends o-f the shaft than need be the case with the shafts 114 and 115. The reason for this difference in location of threaded portions will be made apparent in the following description of the side flap opening section 36. In addition, whereas the shafts 114 and 115 may be identical, the shaft 116 is extended through the right hand side channel 60, this extended end being adapted to receive a crank 120.

The three shafts 114, 115 and 116 are interconnected as clearly shown in Fig. 1 of the drawings by means of chain and sprocket assemblies 121 and 122 sol that any rotation of the shaft 116 by means of the crank 120 will effect a like rotation of the shafts 114 and 115. It will be understood that the sprockets incorporated in the assemblies 121 and 122 are all the same size and, further, that the pitch of the threads on these three shafts are all equal. With this arrangement, traveling nuts mounted on the individual shafts and yet to be described will move simultaneously and at identical speeds.

The shafts 114 and 115 are each provided with a right hand traveling nut 125 and a left hand traveling nut 126. The nuts 125 and 126 associated with the shaft 114 are secured to the guide rail assemblies 112 and 113 by means of appropriate bolts and spacers 127, and those associated with the shaft 115 are similarly secured to the guide rail assemblies by means of bolts and spacers 128. A generally similar interconnection of the guide rail assemblies 112 and 113 with traveling nuts on the shaft 116 enables the assemblies 112 and 113 to be adjusted toward or away from each other simply by turning the crank 120.

The right hand guide rail assembly 112 includes a main guide rail 130 and a receiving guide rail 131 in substantial end to end relationship as clearly `shown in Figs. 1 and 3. The adjacent ends of the rails 130 and 131 are separated vertically by a guide rail spacer 132. As best seen in Fig. 13, these ends are in slight lateral olfset relationship, and a carton stop bracket 133 is provided in the offset. The rails 130 and 131, the spacer 132, and the bracket 133 are all joined together by means of appropriate bolts 134. Fig. 13 also shows the auxiliary guide rail 131 to be cut back at 135 so as to provide a space to receive the pusher plate 109 when the latter is in retracted position. It may be mentioned also that this pusher plate 169 is provided with a notch 136, best shown in Fig. 3, to enable the same to be retracted into the cut out space 135.

The left hand guide rail assembly 113 comprises a main guide rail 138 and a receiving guide rail 139, but in this instance there is no lateral offset and these members are secured together with a vertical spacer 140 interposed therebetween. Preferably, both of the receiving guide rails 131 and 139 have their forward ends formed at an angle as shown in Fig. 1 to enable cartons to be received therebetween smoothly and eiiiciently. In addition, the receiving guide rail 139 is provided with an adjustable carton guide 142 formed as clearly shown in Figs. l, 3 and so that received cartons may be urged toward the receiving guide rail 131.

Proceeding now to the side flap opening section 36, each of the main guide rails 130 and 138 supports a plurality of spaced rollers 145, each of these groups of rollers 145 being mounted on a roller holder 146 pivotally mounted in end support brackets 147. As shown in the drawings, each group of rollers 145 is disposed at an angle to the horizontal, and the pivotal mounting of the holders 146 enables this angle to be varied in accordance with the size of carton to be handled. Appropriate adjusting assemblies 148 each incorporating a screw 149 are mounted on the guide rails 130 and 138 between the end support castings 147 for adjusting the angle of inclination of the rollers 145.

A flap lifter 150 shaped as best shown in Figs. 1 and 3 is disposed on the center line of the unloader 36 between the two sets of rollers 145. This flap lifter 150 is secured in any appropriate manner to a shaft 151 extending between the side channels 60 and 61 and supported therein by appropriate bearings 152. The previously mentioned cam follower arm 96 which cooperates with the flap lifter cam 94 is also secured to the shaft 151, from which it is obvious that rotation of the cam 94 with its shaft 85 effects periodic upward and downward movements of the free end of the flap lifter 150.

A package pate 155 having a plan form as clearly shown in Fig. 1 is disposed on the center line of the unloader 3@ just rearwardly of the flap lifter 150. Preferably, the forward end of the package plate 155 is chamfered on its top surface as shown and may also be chamfered at the forward end of its lower surface. The package plate 155 is supported on a package plate stand 157 which is preferably a casting shaped as shown in Figs. 1 and 3 and which is in turn supported on a pair of package plate shafts 155 extending between the side channels 68 and 61 and secured thereto by means of bolts 159.

Also forming part of the side ap opening section 36 are a right hand and a left hand side flap spreading assemblies 162 and 163, respectively. The assemblies 162 and 163 are supported from transversely extending platelike brackets 164 and 165 secured to the right hand and left hand guide rails 130 and 138, respectively. As is clear from the drawings, the assemblies 162 and 163 are substantially identical except for being of opposite hand. Considering the assembly 162, there is a side flap spreader 168 which preferably takes the form of a casting having a warped surface adapted to move a depending side ap of a carton from a vertical position to a horizontal position as the carton moves along the center line of the unloader 30. A flap opening plow 169 is hinged to the forward end of the spreader 168 by means of a vertical hinge pin 170. The ap opening plow 169 is preferably formed of sheet metal and is generally the shape of an elongated triangle the apex of which is disposed at the center line of the unloader 30. As shown in the drawings, the flap opening plows 169 are disposed vertically. The flap spreading assembly 163 is similar to that just described and includes a spreader 173 and a flap opening plow 174, these members being joined by a hinge 175. Each of the flap opening plows 169 and 174 is provided with a horizontally extending bracket at its apex and these brackets are pinned together by means of a bolt 176.. From the foregoing arrangement, it will be apparent that any movement of the guide rail assemblies 112 and 113 toward and away from each other will induce a like movement of the iiap spreader assemblies 162 and 163. In such movement the spreaders 168 and 173 move bodily with the guide rail assemblies 112 and 113 while the flap opening plows 169 and 174 pivot at their joined apices as well as at the hinges and 175. A right hand traveling nut 177 and a left hand traveling nut 178 are secured to the under sides of the bracket plates 164 and 165, respectively, and these nuts are in turn mounted on the guide rail adjustment shaft 116, as previously indicated.

The trailing end ap opening section 38 comprises a plate-like flap opener 180 having a plan form as clearly shown in Fig. l and including a notched portion 181, the latter for a purpose to appear. The ap opener 180 is supported on a bracket 182 pivotally connected by a hinge pin 183 to rearwardly extending ears 184 of the previously mentioned package plate bracket 157. This arrangement is clearly shown in Fig. 3, as is also a cam arm 185 secured by bolts 186 to the bracket 182. The arm 185 may be adjusted so as to depend from the bracket 182 at any appropriate angle and is secured in adjusted position by the bolts 186. The free end of the arm 185 carries a cam roller 187 which engages the peripheral edge of a cam plate 188 secured to a cam shaft 189. The cam plate 188 is disposed approximately on the center line of the unloader 30 and the shaft 189 is rotatably mounted to the side channels 60 and 61 by means of appropriate bearings 190. 1t will be noted that the shaft 189 extends through the right hand side channel 60 and has a bevel gear 191 secured thereto outside of the channel 60.

The shape of the cam plate 188, which is clearly shown in Fig. 3, makes it apparent that rotation of the shaft 189 will effect periodic raising and lowering of the flap opener plate 180, the movement being in the nature of a sudden and precipitous lowering of the plate 180 followed by a more gradual closing or raising movement. Clearly, the aforementioned adjustability of the arm 185 on the bracket 182 permits the pivotal movement of the plate 186 to be varied in accordance with the requirements of different cartons. It will also be understood that the cam plate 188 may be replaced by a composite assembly comprising adjustable plates adapted to provide further variations in the movement of the plate 180.

A hinged package plate assembly 195 is disposed immediately to the rear of the flap opener 184D and in end to end relation therewith. This assembly 195 includes a hinged package plate 196 joined to a stationary package plate 197 by means of conventional hinges 198. The assembly 195 is mounted on a bracket 199 which is in turn supported by a package plate support bar 200 extending between the side channels 60 and 61 and appropriately secured thereto. As shown in Fig. 3, the bracket 199 has an opening 201 therethrough for accommodation of the guide rail adjusting shaft 116. The

7 bracket199 also has a forwardly extending lip portion 202 which mounts a vertical adjusting screw 203 for adjustably supporting the hinged package plate 196 in an appropriate position for cooperation with the movable flap opener 180, as will be described hereinafter.

The leading end flap opening section 40 comprises a flap opening chain assembly 208 disposed as best shown in Fig. 4. The chain assembly 208 includes two endless roller chains 209 spaced equidistantly from the center line of the unloader 30. These chains 209 are unconventional in that they include special links having laterally extending tabs for support of flap opening slats 210, 211 and 212. As may best be observed from the schematic diagram of Fig. 15, there is a portion of the chain assembly 208 which does not have any of the slats above mentioned. It will also be observed that the slat 210 is the leading slat of the whole group of slats 210, 211 and 212 and it may be mentioned that this slat 210 is formed to a wedge-like cross section with the thin edge in the leading position. The flat slats 211 which are in parallel spaced arrangement following the leading slat 210 each has the upper leading edge rounded olf. The slats 211 are flat to prevent engagement with the trailing edge of a carton flap, as will appear. Following the at slats 211 are the angle slats 212 and it may be mentioned that these angle slats do not have a sharp angular bend but are formed with a radius at their leading edges. Each of the slats 210, 211 and 212 has one end secured to a laterally extending tab on each of the chains 209. The purpose of the open space between the leading slat 210 and the last angular slat 212 will be described hereinafter.

The chains 209 are disposed around upper flight sprockets 21.5 and 216 there being one of each of these sprockets for each chain 209. The sprockets 215 are keyed to a shaft 217 and the sprockets 216 are similarly secured to a shaft 218. These shafts 217 and 218 also support two chain bar asesmblies 219 comprising slat supports 220 and roller chain supports 221 (Fig. The slat supports 220 are formed to the shape shown in Figs. 4 and 5 and are provided at each end with a laterally elongated boss portion 222 by means of which they are mounted to the shafts 217 and 218, which preferably, are provided with grease passages from each end to a point opposite the slat support bosses 222 where they are provided with interconnecting passages to permit lubricating grease to be forced between the shaft and the boss. The roller chain supports 221 are each mounted to a respective slat support 220 by means of appropriate bolt and spacer assemblies 223 (Fig. 7). From the foregoing arrangement it may be seen that the horizontal upper flight of the chain assembly 208 between the shafts 217 and 218 is fully supported for bearing the contents of loaded cartons as will be more fully described hereinafter.

Preferably, the upper edge of each slat support 220 is provided with a replaceable bearing strip of brass or like bearing metal. It may also be mentioned that the depending ange portions of the angular slats 212. are cut back adjacent the ends of these members to provide appropriate bearing contact between the slats 212 and the bearing strips atop the supports 220. Each slat support 220 may also be provided with an appropriate flap stop 224, as indicated in Figs. and 20 to 25.

In addition to the sprockets 215 and 216, the paths of the chains 209 are further dened by lower guide sprockets 225, intermediate guide sprockets 226, and drive sprockets 227, these latter three sets of sprockets being keyed to shafts 228, 229 and 230, respectively. The shaft 228 which mounts the sprockets 225 is adjustable longitudinally of the unloader 30 to provide for tension adjustment of the chain assembly 208. Thus, as best shown in Figs. 3 and 7, the shaft 228 is mounted in bearings 231 slida-bly supported in angular brackets 231a affixed to the side channels 60 and 61. A tension bar 232 secured to each of the bearings 231 extends forwardly thereof and passes through an angular bracket 233 se- "8 cured to the appropriate side channel 60 or 61. A nut 233 is disposed on the free end of each tension bar 232 for adjusting the position of the takeup sprockets 225. An opening 234 is provided in each of the channels 60 and 61 for making this adjustment.

The shafts 217 and 229 each extend between the side channels 60 and 61 being supported therein by suitable bearings 235. The shaft 216, being disposed in line with the upstanding intermediate legs 51 and 54, extends only between these members and is similarly supported by appropriate bearings secured to these legs. The shaft 230 has one end supported in a bearing 237 secured to the left hand side channel 61 while the other end of this shaft passes through the right hand side channel 60 in an arrangement to be more particularly described hereinafter.

The lower flight of the chain assembly 208 receives intermediate support from three pairs of idler sprockets 240 which are rotatably supported on three shafts 241 secured to angle brackets 242 supported from the inturned lower flanges of the side channels 60 and 61 as shown in Fig. 7. Collars 243 disposed on each side of the sprockets 240 maintain the latter in the proper position on the shafts 241. Similarly, the chain Hight between the sprockets 226 and 227 is intcrmediately supported by a pair of idler sprockets 244 rotatably mounted on a shaft 245 extending between the side channels 60 and 61.

The article receiving conveyer 42 comprises an endless belt 250 disposed immediately rearwardly of the upper horizontal ight of the ap opening chain assembly 208. A dead plate 251 is mounted in the space between the adjacent ends of the upper ight of the assembly 208 and the conveyer belt 250 as best shown in Fig. 5. The dead plate 251 is supported at each end by a bracket 252 secured to the inside surface of the appropriate upstanding leg 51 or 54.

The conveyer belt 250 is disposed over an idler pulley 255 and a drive pulley 256 (Fig. 4) and the upper flight of the belt 250 is supported intermediate these pulleys 255 and 256 by means of a roller table 257. The table 257 is conventional and comprises a plurality of rollers 258 disposed in spaced parallel arrangement and supported between longitudinal bars 259. The table 257 is supported by means of angle beams 260 spaced as shown in Fig. 4 and secured to the side channels 60 and 61.

The idler pulley 255 is mounted on a shaft 262 rotatable in bearings 263 slidably supported in angle brackets 264 on the side channels 60 and 61. An adjusting bolt 265 threadedly supported in an idler adjustment bracket 266 is provided for each of the bearings 263 for moving the same so as to effect a proper tension of the conveyer belt 250. The drive pulley 256 is secured to a shaft 268 supported in pillow block bearings 269 attached to the rear of the legs 52 and 55. Besides the pulley 256, the shaft 268 carries a sprocket 270 through which the article receiving conveyer 42 is driven as will appear. A guide rail 272 supported by upright brackets 273 secured to the beams 260 is disposed on each side of the upper flight of the conveyer belt 250 as clearly shown in Figs. 4, 8 and 9.

The flight chain assembly 44 extends from the discharge end of the receiving conveyer section 34 to the rear end of the unloader 30. It comprises two endless chains 275 disposed in parallel and each traversing a path which is clearly indicated in Figs. 3 and 4. The forward end of the assembly 44 is supported on the upstanding legs 50 and 53 (Figs. l, 3 and 6). Thus, referring particularly to Figs. 3 and 6, there is provided a chain tightener shaft 277 mounted in blocks 27S disposed to slide vertically in slots 279 formed in the legs 50 and 53. Each of the blocks 27S is provided with an adjusting screw 280 which extends to the top of the legs 50 and 53 and there has a head 281 which bears against a chain tightener bolt plate 282. Added rigidity for the legs 50 and 53 is provided by means of tie angles 283 extending therebetween.

The chain tightener shaft .T177 has a pair of sprockets 284 mounted for rotation thereon and maintained in position by collars 285 and 286. Immediately below the chain tightener shaft 277 there is a stub shaft bracket 290 secured to the inner face of each leg 50 and 53. These brackets 290 extend rearwardly from the legs 50 and 53 and carry stub shafts 291 mounting idler sprockets 292. At a still lower point on the legs 50 and 53, immediately above the conveyor belt 91, stub shaft brackets 294 are secured to the inner faces of the legs t) and 53 and extend inwardly therefrom to support sprockets 295.

As is clear from the drawings the upper flight of the chains 275 is not supported between the front legs 50 and 53 and the intermediate legs 51 and 54. However, support is provided for the lower flight in the form of angular chain racks 293 which extend in parallel longitudinal arrangement and which are supported from the upper flanges of the side channels 60 and 61 by means of upstanding brackets 299 and tie bars 300. As best shown in Fig. 6, the tie bars 300 are provided with a nut on each side of the brackets 299 so that the racks 298 may be easily adjusted to an appropriate spaced apart position. it will be noted that the rear ends of the racks 293 are opposite the intermediate legs 51 and 54 and at this position, instead of being supported by brackets 299 and tie bars 300, the racks 293 are supported by special brackets 301 secured to the inner faces of the legs 51 and 54. The angle brackets 252 which support the dead plate 251 are notched out as shown at 302 to accommodate the brackets 301.

An idler sprocket shaft 305 is mounted between the intermediate legs 51 and 54 near the upper ends thereof by means of appropriate adapters 336. This shaft 365 supports a pair of sprockets 307 under which the upper flight of the chains 275 pass as clearly shown in Fig. 4. Stub shaft brackets 308, similar to the stub shaft brackets 290, are secured to the legs 51 and 54 just slightly above the dead plate 251 and support stub shaft 309 and idler sprockets 319. Intermediate the shaft 305 and the brackets 308, each leg 51 and 54 is provided with a leg extension 312 secured to its respective leg 51 or 54 by means of a tie plate 313. At their free ends, the exten.- sions 312 are interconnected by a lateral angular brace 314, and each supports a stub shaft bracket 315, a stub shaft 316 and an idler sprocket 317. As clearly illustrated in the drawings, the lower flights of the chains 275 passed beneath the idler sprockets 310 and 317.

As shown in Fig. 4, the upper flights of the chains 275 are unsupported between the intermediate legs 51 and 54 and the rear legs 52 and 55. The lower flights of these chains, on the other hand, are supported between the idler sprockets 310 and the idler sprockets 317 by means of intermediate chain racks 320 which are hung from the stub shafts 309 and 316' by means of hangers 321 and 322. Beyond the idler sprocket 317, these lower chain flights are supported by inclined chain racks 324 the lower ends of which are also hung from the stub shafts 316 by means of hangers 325. The other ends of the racks 324 have slots 326 formed therein for bolted attachment to lower slides 327 movably mounted on the rear legs 52 and 55.

Each lower slide 327 is slidably mounted on an inner face of its respective leg 52 or 55 and is retained by a keeper strip 328 and a rack 329, these members being secured to the legs 52 and 55 with appropriate spacing strips interposed therebetween. The two slides 327 provide bearing support for an adjusting shaft 332 upon which are mounted two pinions 333 which engage the racks 329. The shaft 332 extends through slots 334 formed in the legs 52 and 55 and is formed at one end to receive a crank 335. Each lower slide 327 also mounts a stub shaft 337 which rotatably supports a sprocket idler 338 `under which the chains 275 pass, as shown in Fig. 4.

Each leg 52 and 55 is also provided with an upper slide 340 which is slidably retained by a keeper strip 341 and a rack strip 342 in the same manner as the lower slide 327. Each upper slide 34h also mounts an adjusting shaft 343 carrying a pinion 344, and each is further provided with a stub shaft 345 rotatably supporting a sprocket idler 346. Like the shaft 332, the shaft 343 extends through the slots 334 in the legs 52 and 55 and, again, one end of the shaft 343 is formed to receive a crank 347. Added rigidity for the foregoing arrangement is provided by rear leg top angles 348 and 349 extending between the legs 52 and 55.

A stub shaft bracket 352 is secured in fixed position on. the forwardly disposed surface of each of the legs 52 and 55, and each of these brackets 352 supports a stub shaft 353 and an idler sprocket 354.

As is apparent from the drawings, the two chains 275 move along identical paths spaced equidistantly from the centerline of the unloader 33. The chains 275 are interconnected at predetermined equally spaced intervals by means of pusher bars 355 which extend laterally therebetween and which are secured to special links provided in the chains 275 at appropriate points therealong.

As has been indicated before, each of the continuously moving assemblies above described derives motive power from a single prime mover 46, The prime mover 46, here illustrated as an electric motor, is connected to a conventional variable speed transmission 360 by means of a belt and pulley assembly 361. Both the prime mover 346 and the transmission 366 are `supported from the longitudinal frame members 69 by means of lateral bars 362 and appropriate angle brackets 363. The brackets 363 are slidable upon the bars 362 both for appropriate positioning of the prime mover 46 and transmission 360 and for adjusting the tension of the belt and pulley assembly 361. The output shaft of the variable speed transmission 360 is connected by a chain and sprocket assembly 365 to a main drive shaft 366 rotatably mounted in bearing flanges 367 and 363 secured to the side channels 61 and 60, respectively.

As is clear from Fig. 2, the flange 368 is disposed on the outside of the channel 60 and provides direct bearing support for a sleeve 359 within which the shaft 366 is rotatable. A shear pin collar 370 is secured to the sleeve 369 at its outer end and is abutted by a shear pin hub 371 secured adjacent the outer end of the shaft 366. A replaceable shear pin 372 interconnects the members 370 and 371 so that rotation of the shaft 366 normally effect-s like rotation of the sleeve 369. Preferably, the extreme outer end of the shaft 366 is provided with a square tip 373 by means of which the members 37 and 371 may be aligned for insertion of a shear pin 372.

Two gears 375, each provided with a hub 376, are secured for rotation with the sleeve 369. One of the gears 375 engages a gear 377 for transmitting power to the flap opening chain assembly 208 and the other gear 375 engages a gear 373 for transmitting power to the remaining continuously moving assemblies of the unloader 30.

Considering first the drive for the flap opening chain assembly 203, the gear 377 is mounted for rotation with a sleeve 380 rotatably supported in a bearing flange 381 secured to the side channel 60. The sleeve 330 rotatably supports one end of the previously mentioned shaft 230, the other end of this shaft being supported in the aforementioned bearing 237 secured to the side channel 61 (Fig. 2). Both the sleeve 380 and the shaft 230 extend beyond the right hand side channel 69 where the former carries an adjusting hub 332 and the latter carries an abutting adjusting flange 333. The hub 332 is keyed to the sleeve 330 and the flange 333 is keyed directly to the shaft 230. The abutting members 382 and 383 are ysecured together by means of bolts which pass through slotted holes in one member to be received in threaded holes r-11 in the other member and which thereby provide adjustability between the gears 377 and the previously mentioned sprockets 227 which directly drive the chain assembly 208.

The gear 378 in mesh With the gear 375 is mounted on the input shaft of a conventional speed reducing gear box 385 secured to the.- outside of the side channel 60 (Fig. 2). The gear box 385 has twin output shafts 386 both of which rotate in a counterclockwise direction when viewed from the front of the unloader 30. These output shafts 386 are connected by individual couplings 387, one to a forwardly extending line shaft 388 and the other to a rearwardly extending line shaft 389.

Considering rst the forward extension from the gear box 385, the line shaft 388 extends parallel to the side channel 60 and is supported from the latter by means of a pillow block bearing assembly 390. At its forward end, which is located opposite the previously mentioned ap opening plows 169 and 174, the line shaft 388 mounts an adjusting flange 392 (Fig. l) which is adjustably secured by means of a well known slot and bolt arrangement to a hub ange 393. The hub flange 393 rotatably supports a bevel gear 394 in meshing engagement with the previously mentioned bevel gear 191 secured to the cam shaft 189. The gear 394 is keyed to another line shaft 395 also supported from the side channel 60 by means of a pillow block bearing assembly 390 and which terminates at a point opposite the receiving conveyer section 34. Like the shaft 388, the shaft .395 mounts at its forward end an adjusting ange 392 adjustably secured to a gear hub flange 393 which in turn supports a bevel gear 396 in meshing engagement with the bevel gear 87 secured to the shaft 85. The bevel gear 396 is keyed to a line shaft 397 which is supported at its forward end by means of still another pillow block bearing assembly 390 secured to the side channel 60.

Considering now the rearward extension from the gear box 385, the line shaft 389 is supported by two more spaced pillow block bearing assemblies 390 secured to the side channel 60. A bevel gear 400 is mounted for rotation with the shaft 389 at a point intermediate these latter bearing assemblies 390 so as to engage a mating bevel gear 401 keyed to the end of a cross shaft 402 rotatably supported in bearing flanges 403 secured to the side channels 60 and 61 (Fig. 2). The shaft 402 carries a sprocket 405 provided with an endless chain 406 in driving engagement with the previously mentioned sprocket 270 keyed to the shaft 268.

The end of the line shaft 389 which is disposed rearwardly of the rearmost pillow block bearing assembly 390 carries an adjusting ange 408 adjustably secured through a suitable bolt and slot arrangement to a shear pin flange 409, the latter being rotatably mounted on the shaft 389. The shear pin ange 409 in turn abuts a shear pin hub 410 which is also rotatable upon the shaft 389 and which is connected by a shear pin 411 to the shear pin ange 409. A bevel gear 412 is supported in and keyed to the shear pin hub 410. The gear 412 meshes with a bevel gear 413 keyed to the lower end of a vertical shaft 414, as best indicated in Fig. 8.

The shaft 414 is supported near its lower end by a pillow block 415 secured to the side channel 60, the weight of the shaft 414 being taken by a thrust bearing assembly 416 which rests on top of the pillow block 415 and supports the shaft 414 through a collar 417 secured thereto. At is upper end, the shaft 414 is supported by a pillow block 418 mounted on a pillow block bracket 419 secured near the upper end of the rear leg 52. Preferably, a thrust bearing assembly 420 is provided for added support for the shaft 414, the latter bearing being disposed on top of the pillow block 418 and being in turn surmounted by a collar 421 secured to the upper end of the shaft 414. Intermediate its ends and as shown in Fig. 8, the vertical shaft 414 is provided with a keyway 424 12 of substantial length. A bevel gear 425 is mounted on the shaft 414 adjacent this elongated keyway 424 and is provided with a key secured for vertical sliding movement with the gear 425, the latter being freely slidable along the shaft 414 in the vicinityI of the keyway 424. The gear 425 meshes with a bevel gear 426 secured to an adjacent end of the shaft 345 which supports the drive sprockets 346. An angle bracket 428 is disposed on the shafts 345 and 414 as clearly illustrated in Fig. 8 and serves to maintain the bevel gears 425 and 426 in proper meshing engagement. At the same time, this angle bracket 428 causes the gear 425 to follow the vertical movement of the shaft 345 with the aforementioned upper slides 340.

The unloader 30 is provided with auxiliary end ap opening devices in the form of a rear flap opening device 430 and a front iiap opening ydevice 432 (Figs. 3, 4 and 7). The device 438 comprises an upper pivot shaft 433 and a lower pivot shaft 434 each rotatably supported in bearings mounted on the side channels 60 and 61 and each mounting centrally thereof pivot arms designated 435 and 436 fixed to the shafts 433 and 434, respectively. The swinging end of each of the arms 435 and 436 is pivotally connected to an upstanding valve body 437. The valve body 437 has a vacuum passage extending from bottom to top thereof and is provided with a laterally movable slide valve spring biased to a position which obstructs the vacuum passage through the body 437. A bell crank 439 is pivotally mounted to the body 437 with one arm abutting the slide valve and the other arm being pivotally connected to the armature of a solenoid 441. Actuation of the solenoid 441 causes the slide valve to be moved to a position which clears the vacuum passage through the body 437. The arrangement of parts which enables this electrically actuated clearance through the body 437 is depicted in Figure 7 in respect to a similarly arranged valve body 467, slide valve 468, bell crank 469, solenoid armature 470, and solenoid coil 471.

The upper end of the valve body 437 is provided with a iiexible cup-like suction tip 442 having a pivotal connection to the valve body 437 and having a passage therethrough which communicates with the passage in the valve body 437. A flexible hose 444 connects the lower end of the valve body 437 with a vacuum line 445.

The solenoid 441 is supported from the Valve body 437 by means of an appropriate bracket 447 and this whole assembly is movable in a generally vertical direction when the pivot shafts 433 and 434 are caused to move. For this latter purpose, the shaft 434 has a spur gear 448 keyed thereto and in meshing engagement with a rack member 449 mounted at the free end of a piston rod 450 adapted to be actuated by an air cylinder 451 mounted on angle supports 452 secured between the side channels 60 `and 61. A rack slide 454 mounted on the aftermost of the previously mentioned package plate shafts 158 backs up the rack 449 to insure proper mating engagement with the spur gear 448. From the foregoing arrangement, it is obvious that actuation of the air cylinder 451 is adapted to effect vertical movement of the valve body 437 and the parts attached thereto, and it will be noted from Figs. 1 and 3 that the suction cup 442 is disposed so as to pass through the previously described slot 181 in the movable flap opening plate 180.

As illustrated in Fig. l, the lower pivot shaft 434 extends through the side channel 60 and is provided at its end with a limit switch finger 455 adapted to actuate a switch 456. It will be understood that the switch 456 controls the actuation of a valve solenoid (not shown) which is effective to reverse the retraction stroke of the air cylinder 451, the arrangement being such that pivotal movement of the shaft 434 in a direction which raises the valve body 437 causes this valve solenoid to be actuated just as the suction cup 442 reaches the peak of its movement upwardly through the slot 181. The means for initiating the retraction stroke of the cylinder 451 and, hence, the upward movement of the cup 442 will be described presently.

The device 432 is generally similar to the device 430. As shown in Fig. 4, it has an upper pivot shaft 463 and a lower pivot shaft 464, the former being non-rotatably and the latter being rotatably mounted between the side channels 60 and 61. Upper pivot arms 465 mounted for pivotal movement on the shaft 463 and retained by collars 466 have their free ends pivotally -connected to a valve body 467 similar to the previously described valve body 437. Like the body 437, the valve body 467 is provided with a spring biased plunger valve and a bell crank adapted to be moved by a solenoid. Thus, as clearly shown in Fig. 7, a plunger 468, a bell crank 469, a solenoi-d armature 470 and a solenoid coil 471 are cooperatively assembled vas described for `the corresponding elements of the valve body 437.

Theupper end of the valve body 467 is provided with a liexible cup-like suction tip 472 having a pivotal connection to the valve body 467 and having7 a passage therethrough which communicates with the passage in the valve body 467. A flexible hose 473 connects the lower end of the valve body 467 with the previously mentioned vacuum line 445.

A pair of lower pivot arms 474 having a common hub 475 is rotatably mounted on the lower pivot shaft 464. The hub 475 has a ange 476 adapted for adjustable attachment to a anged sleeve 477 which is keyed to the shaft 464. By means of a suitable slot and bolt arrangement, the lower pivot arms 474 may be adjusted to an appropriate angular position with respect to the sleeve 477. Referring7 to Fig. 4, the sleeve 477 has an arm 478 pivotally attached to a connecting nut 479, the other end of the latter being connected through a stroke adjusting pin 480 and another connecting nut 481 to a piston rod 482 adapted for reciprocation by an air cylinder `433. The end of the cylinder 483 opposite that from which the piston rod 482 projects is pivotally attached to a bracket 484 supported by angle supports 485 secured to the side channels 60 and 61.

Like the shaft 434, the lower pivot shaft 464 extends through the side channel 60 and is provided with a limit switch linger 48S adapted to actuate a limit switch 489. The limit switch 489 is interconnected with a valve solenoid (not shown) which is effective to reverse the upward movement of the suction cup 472 in the same manner as described for the device 430.

It may be mentioned at this point that whereas the operation of the flap opening devices 430 and 432 is generally similar, it will nevertheless be noted that the specic movements of the suction cups 442 and 472 are different. This is due to the different arrangement of the pivot shafts and the upper and lower pivot arms in the two devices. Thus, as clearly shown in Fig. 3, it is apparent that the suction cup 442 of the device 430 will be raised and lowered in a generally vertical direction whereas the suction cup 472 of the device 432 will be advanced, not only upwardly but also forwardly of the unloader 30 and will be retracted generally downwardly and rearwardly. The significance of this latter movement will be made clear hereinafter.

The periodic movements of the ap opening devices 430 and 432 are controlled from the line shaft 388 and thus are coordinated with the movable conveying elements of the unloader 30. Both the air cylinder 451 and the air cylinder 483 receive compressed air from an appropriate supply through conventional electrically operated air valves (not shown). These air valves, one for each cylinder, are actuated through individual limit switches 490, there being one of these switches for each of the devices 430 and `4552. The two `switches 490, as shown in Fig. l, are mounted on suitable brackets secured to the side channel60 adjacent the line shaft 388. For actuating the limit switches 490, individual dial plates 492, each provided with an adjustable lobe 493, are mounted on the shaft 388 for rotation therewith.

It will be understood, lthen, that actuation of a partcular switch 490 initiates the movement ot the associated device 430 or 432, which movement, as previously described, includes automatic reversal upon actuation of the appropriate switch 456 or 4W.

Adjacent each switch `490 there is a switch 494 adapted to be the appropriate switch 494. flt will be understood that each of the switches 494 is connected to a respective one of the solenoids 441 and 471, so as to control the extension of vacuum to the suction tips 442 and 472.

The unloader 30 is adapted to move cartons at a substantially constant rate of speed therethrough, but, as will be more fully explained hereinafter, the arrival of a loaded carton onto the iiap opening chain assembly 208 tends to effect an advance faster than the desired speed. Thus, the unloader 30 includes a pair of squeezers 500, one being adjustably mounted by means of an appropriate slot and bolt arrangement to each guide rail 138 disposed along the upper horizontal llight of the flap opening chain assembly 208. As shown in Fig. l, the squeezers 500 are tapered at their forwardly disposed ends to receive and press against the sides of a carton moving therebetween.

For `additional retardation of cartons moving through the unloader 30 at this point, a pair of retarding arm .assemblies 505 is provided, one of these assemblies 505 being mounted on each of the side channels 60 and 6i by means of a bracket 506 and an associated spacer 507 (Figs. 1 and 7). Each retarding arm assembly 505 includes an elongated .arm 508 disposed transversely of the unloader 30 and pivotally mounted to its bracket 506, the pivotal mounting being intermediate the lateral extension of the arm 508. At the outer end of each arm 508 a pair of tension springs 510 are connected so as to bias these outer ends toward the rear of the unloader 30. The springs 510, as shown in Fig. 2, each have one end connected to an arm 508 and the other end connected to an angle bracket 511 secured to the side channel 6i) or `61. A stop bracket assembly 512 mounted on each bracket 506 provides an adjustable means for limiting the forward movement of the free inner ends of the arms 508. Preferably, each arm 50S is connected at its outer end with a conventional snubber assembly, for example, a common door check cylinder 513, to reduce the shock of the spring actuated return movement of the -arms 50S after a carton has passed therebetween.

A third device for controlling the movement of a carton in the vicinity of the llap opening chain 20S is provided in the form of a holddown shoe .assembly 515. The assembly 515 comprises an elongated plate-like shoe member 516 bent to the form clearly shown in Fig. 4 and secured at the lower end of -a shaft 517 mounted for vertical adjustment in a collar 518 secured to a cross angle 519 extending between the legs 51 .and 54. A thumb screw 520 is provided to secure the assembly 515 in adjusted position.

Once the carton has advanced beyond the upper flight of the flight opening chain assembly 208, it. is ready to be taken oit the unloader 30 and for this purpose there is provided carton take-off means comprising a pair of carton take-off hinges 522 attached to the dead plate 251 adjacent the lateral ends thereof and pivotally supporting the lower end of an inclined carton take-off rail 523 (Fig. 5). To each carton take-oit rail 523 there is attached a carton take-off extension 524, the attachment between -these members being in the form of a tie plate 525 providing for an adjustable inclination of the extension 524 as is clear from Fig. 4. A slot 526 is formed adjacent the upper end of each of the inclined extensions 524 and these ends are supported by a bar 527 which passes through the slots 526 and is supported from. its ends by carton take-off brackets 528 secured to the outside surfaces of the chain rails 324. This hanger construction is clearly shown in Fig. 8 wherein it will also be seen.

that the shaft 527 is provided with collars 529 for maintaining a proper spacing of the carton take-off extensions 524 at this point of support.

Referring once more to Fig. 5, the dead plate 251 has a shallow cut out portion for receiving a lateral strip 532 to the center of which is secured a partition tongue 533 having the approximate shape of the hinges 522 and disposed in parallel therewith. From Fig. 2 it will be noted that the strip 532 is slotted near each end so that the tongue member 533 may be shifted laterally of the center line of the unloader 31) and secured in adjusted position by means of screws 535. At its rear end the tongue 533 is pivotally connected to a partition tongue extension 536, a single hinge pin 537 being used to make the pivotal connection between these members as well as between the hinges 522 and the extensions 523. The partition 4tongue extension 536 extends on an inclination so as to be parallel with the carton take-off extensions 524 and is supported at its upper end on the same shaft 527 where it is adjustably retained by collars 538. It will be noted that this whole partition tongue construction is lateral-ly movable for desired adjustment with respect to the center line of the unloader 30. At its extreme upper end, the partition tongue extension 536 is provided with a carton discharge plate 540 shaped as clearly indicated in Figs. 4 and 8.

Operation As previously indicated, all of the continuously moving elements of the unloader 30 are powered by the single prime mover 46. Thus, in order to prepare the unloader 30 for operation it is only necessary to energize the prime mover 46 and, of course, the vacuum and air systems associated with the unloader 30.

The drive from the prime mover 46 extends through the variable speed transmission 360 for appropriate speed adjustment and is transmitted to the main drive shaft 366 carrying the drive gears 375. As has been previously described, the drive from the shaft 366 extends both to the flap opening chain assembly 208- -and to the conveyor assemblies at the forward and rear ends of the unloader 30. It also extends by means Vof the vertical line shaft 414 to the flight chain assembly 44. It is clear, therefore, that each of these conveying assemblies continues to move as long as the prime mover 46 is energized.

Loaded cartons are fed into the unloader 30 with the contents of the cartons in the position in which it is desired that they be unloaded. The loaded cartons may be placed manually lon the conveyer belt 91 at the forward end of the unloader 30 or they may be conveyed automatically to this point by an auxiliary conveyer such as 545 (Figs. l and 3). As the cartons are placed upon the belt 91, the carton deiiector 142 urges them to the right hand side of the receiving conveyer section 34 so that they slide along the guide rail 131. Normally the cartons are conveyed by the belt 91 until they reach the stop plate 133 where they are prevented from further forward movement. From Fig. 3 it is apparent that cartons must he held at the carton stop plate 133 until such time as they may be coordinated with the moving flight chain assembly 44 so that a bar 355 of the assembly 44 does not descend upon the top of the carton. As is evident from the foregoing description, however, the movement of the ight chain assembly 44 is coordinated with the movement of the cam 93 rotated by the receiving conveyer section drive shaft 35. The aforementioned predetermined spacing of the bars 355 of the ight chain assembly 44 is such that one of these bars passes a given point for each revolution of the shaft 85 and hence for each revolution of the feed cam 93. Since each revolution of the cam 93 effects a lateral back and forth movement of the bracket 11i@ and also of the attached feed shoe 1119, it is clear that any carton which is in position against the carton stop bracket 133 will be pushed bodily loose therefrom and freed for advance to 16 the discharge end of the receiving conveyer section 34. Very soon thereafter, one of the bars 355 of the ight chain assembly 44 moves into position in back of the carton thus released and pushes the carton before it from this point to the end of its travel through the unloader 30.

As the loaded carton leaves the receiving conveyer section 34 it is supported on the inclined rollers 145 of the side ap opening section 36. The inclination of the rollers is adjusted to permit the side flaps to open slightly, but not enough to cause the end aps to drop or the contents of the cartons to drop out. The carton is advanced until its forward end approaches the chamfered forward end of the package plate 155. At this point the end ap at the leading end of the carton rides up on the package plate 155 but the side flaps, due to their slightly open position as aforementioned, pass beneath the package plate 155. It will be noted, however, that the end ap at the trailing end of the carton approaches the package plate 155' with its free edge foremost, and it is evident that the inclination of the side flaps would very likely permit this end flap to open sufficiently at this point to cause its free edge to catch under the package plate 155 if means were not provided for lifting the trailing end flap to fully closed position. It is for this latter purpose that the flap lifter is provided.

As previously described, the flap lifter 150 is caused to move up and down by virtue of the arm 96 operated by the cam 94 carried on the shaft 85. Since, as before mentioned, the shaft 85 is coordinated with the movement of the predeterminately spaced bars 2'75, it is evident that the up and down movements of the ap lifter 150 will be also coordinated with the passage of a carton thereover. Thus, as the leading end of the carton approaches the package plate the flap lifter 150 is in its down position and as the carton passes up on to the package plate 155 the ap lifter 150 raises to support the trailing end flap so as to ensure its passing onto the top of the package plate 155.

As the loaded carton moves on through the side iiap opening section 36 the side flaps of the carton which now hang over the side edges of the package plate 155 are moved into contact with the flap opening plows 169 and 174 which cause them to open to a straight down position and as the carton continues to move the flaps ride up on the iiap spreaders 168 and 173 until they are each in a horizontal position having been pivoted degrees from their original closed positions.

During the final opening movement of the side aps, the loaded carton moves onto the trailing end flap opening section 38. Figs. 16 through 19 depict the sequential opening of the trailing end flap 550 of a carton 551. Thus, as is apparent from Fig. 16, the carton 551 is pushed 01T the package plate 155 onto the movable package plate 180 and then onto the hinged plate 196. As the leading half of the carton 551 moves across the movable plate 180, the latter is in its raised position as e11- forced by the cam 188 acting through the arm 185. Then as the leading end flap 552 passes completely on to the hinged plate 196 and as the leading edge of the trailing end flap 55) approaches the gap between the plates 180 and 196 the cam 188 rotates to a point where the plate 180 is allowed to drop abruptly to a position below the plate 196, as indicated in Fig. 17. As is clear from Figs. 17 and 18, continued movement of the carton 551 causes the leading edge of the trailing end ap 550 to enter the gap between the plates 180 and 196 and thus to be swung about its pivotal connection to the carton 551 while the contents of the carton are supported by the hinged plate 196. As the lcarton continues to move the plate 180 is again caused to raise through continued rotation of the cam 138 so that the trailing end ilap 550 may be dragged back through the gap between the plates 1811 and 196 without damage as indicated in Fig. 19.

As soon as the loaded carton passes beyond the trailing end ap opening section 38 it enters upon the leading end Y asi 5,140

ap' opening section dt). Figs. 2O through 25 show the sequential operation of this section in opening the leading end flaps 552 of the carton` 551. From Fig. 20 it will` be noted that as the carton 551 is moved over the stationary plate 197 to a position where the leading end ap 552 is about to drop oit the rear end of the plate 197, the continuously moving flap opening chain assembly 208 is' in the position, as also` depicted in Fig. l5, where the gap between the leading chain slat 2&0' and the trailing bar 212 is in such position that the flap 552 will drop on to the llap stop 224 as illustrated in Fig. 2l. As previouslymentioned, however, the flap opening chain assembly 208 moves at a speed considerably greater than that ofthe flight chain assembly lid, the difference in speed being' in the nature' of fourto one, so that the leading chain slat 210 quickly catches up with the tlap 552, as shown in Fig; 22. From this point on, it is obvious that even" though the contents of the carton 551 should drop therefrom they will be supported on the chain assembly 2G81 Figs. 23, 24' and 25 depict clearly the manner in which the leading end flap 52 is swung by thefaster moving chain assembly Ztl@ to a fully open position with thel contents ofthe carton 551 being, deposited on top of this chain' assembly 208.

It" is` during the period` while the carton and its contentsrest upon the chain assembly 2h18 that the squeezers 50'() `and the retarding arm assemblies 505' operate as previously mentioned to restrain the carton from moving faster than" the bars 355.

With alll ot its flaps fully opened, the carton may now be removed from the contents leaving the latter to be moved over the dead plate 251 onto the conveyer belt 25th Thus, each carton as it leaves the flap opening chain assembly 208 passes on to the carton take-ott rails 523 and is carried to the upper end ofthe extensions Sill-4il to be discharged at the extreme rear end of the unloader Sil. if the unloaded carton has a partition section therein, the partition section is retained in the carton by the partition tongue arrangement described above. As was' mentioned describing the partition tongue arrangement` thesel elements are transversely adjustable so that they may bef moved to a position where adjacentunloaded articlesmay pass on' either side thereof. The now unloaded articles ofthe original* loaded carton are conveyed by the moving conveyor belt 2150i to the discharge end thereof where they may be received onto apparatus for unscrarnbling, lilli'ngor otherwise handlingthem.

Inasmueh as the present unloader 30 is particularly adapted to handle loaded cartons at relatively high speeds, the auxiliary flap opening devices 434) and 4'32" are provided toensure that the trailing end ap andthe leading end liap's drop instantly as required by the operations depicte'd in sequence in Figs. 16 through 25. It is obvious thatfwhere the loaded contents of a carton are of light Weight or where the ilaps are relatively stii, the desired speed of movementthrough` the unloader 30 may be such that thesetaps tail to drop fast enough to eliect the desiredi opening operations. As previously described, the movements of the ap opening devices 430 and 432 are timed by switches actuated by movement of the line shaft 388 which thereby coordinates movement of the devices 4330* and 432 with movement of the cartons through the unloader 30. The operation of these devices has been described and it is only necessary to` mention here that the' suction cup 442 of the devicey @bis timed toffpass upwardly throughthe slot 131 in the plate 1.180' as the trailing end hap moves thereover. The vacuum which exists at the suction cup at this time secures the same `to the hapf and the immediately following downward movement of the valve body 437 causes the hap to be drawn into the gap between the plates 1180 and 19o to forestall any failure of this flap to enter the gap in the manner previously described.

As is clear from Figs. 3 and 4, the. device 432 being disposedl WithinA the flap opening1 chain assemblyZtlS is adapted to move upwardly at the instant the leading end l'ap moves ott the plate 197" whereupon the vacuum eX- isting at this time in the suction cup 472 causes the same to secure itself to the leading end ilap. The" retractin-g movement of the suction cup 472, being in a direction which `is both downward and toward the rear of the unr loader 30 ensures that the leading end flap will be drawn down into the gap in the chain assembly 2h08' for the previously described opening operation.

The present unloader 36 is adapted to` handle cartons of diierent size, including cartons` of diiierent widths as well as cartons of different depth. In addition, the present unloader 3`0 is adapted to handle cartons of different lengths. As is apparent from` the foregoing description, the adjustment for different width cartons Within the spacing of the flight chains 275 is quickly eiiected through movement of the crank which causes not only the several guide rail assemblies, but also the inclined rollers and the side flap opening assemblies 162 and"16`3` to move to appropriate positions for the width of carton to be unloaded. l t

For cartons of different` height, the carton take-oit extension as well as the rearmost end ofthe ight chain assembly may be adjusted by means of the cranks 335 and 347 to vary the height to which the empty carton is raised to clear the unloaded contents.

As to cartons of dilerent lengths, the foregoing.` description of adjustable connections between the elements which drive the conveying assemblies and which time and coordinate the several operations of the unloader 3'0 make it quite clear that adjustments maybe made to coordinate the operations for changes in the length of cartons to be handled'.

Clearly, there has been describedI an'unloader which` fullls the objects and advantages sought'4 therefor, particu- Vlarly in respect to a construction for and method` of opening the carton end flaps.

It is to be understood that the foregoing description and the accompanying drawings have been given by way of illustration and example. It is also to be understood that changes in form 4of the elements, rearrangement of parts or steps, and substitution of equivalent elements or steps, which will be obvious to those skilled in the art, are contemplated as within the scope of the present invention which is limited only by the claims which. follow.

What is claimed is:

1. In a cart-on unloading machine for opening the bottom unsealed aps of a carton, -in combination, mechanism` for moving the bottom trailing enduap of the carton from closed position through one hundred eighty degrees to open position comprising a rst pivotally mounted plate `over which the carton is moved, a second plate spaced from the first plate to provide augap therebetween, said lirst plate being movable downwardly about its pivot as the carton is moved thereover to permit the trailing hap to drop a little under the Weight of the contents, auxiliary means for positively engaging and initially pivoting the trailing flap as it passes over said first piate to insure its downward pivotal movement, thefree edge of said second plate being disposed above thelowered position of .said `first plate to permit the free edges ot the trailing Hap to pass `there under and to be pivoted. through the remainder of substantially one hundred `eighty degrees as the carton is moved on through said machine, and means to return said rst plate to its original position.

2. In a carton unloading machine, in combination, mechanism for pivoting the bottom unsealed leading flap of a carton through substantially one hundred eighty degrees comprising an endless conveyer yincluding a leading cross member and trailing cross members, a space between the leading cross member and the last trailing cross member, means for moving a loaded carton with unsealed bottom aps and spread side aps into position with the leading `flap over the said Aspace of the conveyer, stop means limiting pivotal drop of the leading flap, said con-l veyer moving at a speed in excess of that of the carton to permit movement of said leading cross member between the leading ap and contents prior to drop of the leading ap from said stop means, said continued movement of said leading cross member at the greater speed moving said leading ap to a horizontal position at one hundredeighty degrees from its original position, said trailing cross members supporting the carton contents, and means preventing the carton and conveyor supported contents from moving at the speed of the conveyor.

3. In a carton unloading machine, in combination, mechanism for pivoting the bottom unsealed leading flap of a carton through substantially one hundred eighty degrees comprising an endless conveyer including a leading cross member and trailing cross members, a space between the leading cross member and the last trailing cross member, means for moving a loaded carton with unsealed bottom ilaps and spread side flaps into position with the leading flap over the said space of the conveyer, stop means limiting pivotal drop of the leading flap, means for positively engaging and initially pivoting the leading flap as it moves into position over said conveyer space to insure its downward pivotal movement, said conveyer moving at a speed in excess of that of the carton to permit movement of said leading cross member between the leading ap and contents prior to drop of the leading ap from said stop means, said continued movement of said leading cross member at the greater speed moving said leading flap to a horizontal position at one hundred eightly degrees from its original position, said trailing cross members supporting the carton contents, and means preventing the carton and conveyer supported contents from moving at the lspeed of the conveyer.

ying cross members, a space between the leading cross member and the last trailing cross member, and means for moving a loaded carton with unsealed bottom flaps and spread side aps into position with the leading lap `over the said space of the conveyer thereby enabling said leading vflap to pivot downwardly into said space, said conveyer moving at a speed in excess of that of the carton to permit movement of said leading cross member between the leading ap and contents prior to drop of the leading flap from a closed position to a 90 open. position said continued movement of said-leading cross member at the greater speed moving said leading flap to a horizontal position at 180 from its original position, said trailing cross members supporting the carton contents.

5. In a carton unloading machine, in combination, mechanism for pivoting the bottom unsealed leading ap of a carton through substantially 180 comprising an endless conveyer including a leading cross member and ytrailing cross members, a space between the leading cross 'moves into position over said conveyer space to insure its downward pivotal movement.

6. The combination of claim l wherein the first plate is provided with a longitudinal slot in communication with its free end, said auxiliary means comprising reciprocable flap engaging means mounted for movement upwardly through said slot.

7. The combination of claim 6 wherein said ap engaging means comprises valve means provided at one -end with a resilient suction cup, said valve means being 2p adapted to extend a vacuum to the interior of said suction cup, means mounting said valve means for reciprocal movement whereby said suction cup may be moved up through said slot for vacuum engagement with a trailing end carton ap, means including a power cylinder for reciprocating said valve means including said suction cup, means including electrically actuated means for operating said valve means to extend a vacuum therethrough, and means including electrical switch means for coordinating the operation of said power cylinder and said electrically actuated means with the oscillation of said first plate.

8. An automatic carton unloader comprising, in combination, means for receiving and advancing loaded cartons, means for opening the lower side aps of said cartons through at least means for opening the lower end aps of said cartons through at least 90, means for receiving and supporting the contents of the thus opened cartons, and means for withdrawing the opened cartons from the supported contents thereof, said means for opening the lower end flaps including means for opening the leading lower end flap comprising a moving belt assembly for supporting a loaded carton having at least three of its lower flaps in open position, said belt assembly including an endless belt having an opening therein for receiving said leading lower end flap, and means for advancing said belt along a horizontal flight below said carton and from rear to front thereof at a rate of speed which exceeds that of the advancing loaded cartons.

9. The combination of claim 8 wherein the endless belt comprises a pair of endless side chains and a plurality of parallel transversely disposed cross members adapted to serve as a moving platform for supporting the contents of a loaded carton.

l0. An automatic carton unloader comprising, in combination, means for receiving and advancing loaded cartons, means for opening the lower side tlaps of said cartons through at least 90, means for opening the lower end flaps of said cartons through at least 90, means for receiving and supporting the contents of the thus opened cartons, and means for withdrawing the opened cartons from the supported contents thereof, said means for opening the lower end flaps of the cartons comprising a movable flap opening chain assembly provided with a gap for receiving the leading lower end flap of a moving carton, means for advancing the chain assembly past the cartons from rear to front thereof, and auxiliary flap opening means adapted to engage a lower end flap and to pivot the same downwardly into said gap, said auxiliary ap opening means comprising valve means provided at one end with a resilient suction cup, said valve means being adapted to extend a vacuum to the interior of said suction cup, means mounting said Valve means for reciprocal movement whereby said suction cup may be moved up through said gap for vacuum engagement with a leading end carton flap, means including power means for reciprocating said valve means including said suction cup, means including electrical means for operating said valve means to extend a vacuum therethrough, and means including switching means for coordinating the operation of said power means and said electrical means with the movement of said ilap opening chain assembly.

11. The unloader of claim 9 wherein the plurality of cross members includes a leading cross member, a plurality of intermediate cross members, and a trailing cross member in consecutively adjacent substantially equally spaced arrangement, there being a substantial gap between the trailing cross member and the leading cross member.

12. The unloader of claim 11 wherein there is a stationary package plate for slidably supporting the advancing carton, the upper horizontal flight of the endless chain assembly being disposed slightly below, but otherwise in extension to said package plate, the means for El receiving and advancing loaded cartons including means for advancing the same at equally spaced intervals over said package plate and onto said chain assembly, and means for moving said chain assembly at an integral multiple of the speed of advance of the loaded cartons, whereby consecutive advancing cartons may be advanced onto the endless chain assembly in substantially identical relation to the leading cross member.

13. The unloader of claim l2 wherein adjustable guide means are provided for guiding the cartons over the upper horizontal flight of the endless chain assembly, said guide means having adjustable squeezing means mounted thereon for restraining the cartons against advance at the speed of the chain assembly.

14. The unloader of claim 13 with the addition of gate-like carton retarding means, said means comprising a pair of pivotally mounted retarding arms adapted to extend transversely of the path of the advancing cartons, spring means biasing said arms in a direction opposed to deflection thereof by an advancing carton, snubber means to reduce the speed of the spring enforced return movement of the retarding arms after ideection thereof by an advancing carton, and adjustable stop means for retaining the retarding arms in a position transversely of the path of the advancing cartons in the absence of a de- 10 fleeting force.

References Cited in the file of this patent UNITED STATES PATENTS Seidel et al. May 20, 1952 

